Weaving with effect from orientation of high and low pile



1958 c. H. MASLAND 2ND 2,820,484

WEAVING WITH EFFECT FROM ORIENTATION OF'HIGH AND LOW PILE Filed Dec. 25', 1953 5 Sheets-Sheet 1 ZNVENTOR Clara e; A. Mas azzaf, 2M

m 1953 c. H. MASLAND 2ND 2,820,484

WEAVING wrrn EFFECT FROM ORIENTATION OF HIGH AND LOW PILE Filed Dec. 23.51953 '5 Sheets-Sheet 2 l VENTOR l C/izarles/i/flas 4724,27!

Jan. 21, 1958 c, MASLAND 2 2,820,484

WEAVING WITH EFFECT FROM ORIENTATION OF HIGH AND LOW FILE Filed Dec. 25, 1953 5 Sheets-Sheet 3 65 (9 All;

- Jan. 21, 1958 c. H. MASLAND 2ND 2,820,484

WEAVING WITH EFFECT FROM ORIENTATION OF HIGH AND LOW PILE Filed Dec. 23, 1955 v 5 Sheets-Sheet 4 I INVENTOR Car/es MMas/zzzand.

Jan. 21, 1958 WENING WITH EFFECT FROM ORIENTATIQN OF HIGH AND Low PILE Filed D60. 25, 1953 C. H. MASLAND 2ND 5 Sheets-Sheet 5 INVENTOR 6% aires llaszndj, 2M

ATTORNEYS WEAVING WITH EFFECT FROM ORIENTATION OF HIGH AND LOW PILE Charles H. Masland 2nd, Carlisle, Pa., assignor to C. H.

Masland & Sons, Carlisle, Pa., a corporation of Pennsylvania Application December 23, 1953, Serial No. 399,878

3 Claims. (Cl. 139-39) The present invention relates to weaving of pile fabrics, particularly carpets and rugs, having a plurality of pile heights in the same transverse row, and to the fabric produced.

The present application is a continuation in part of my application Serial No. 144,764, filed February 17, 1950, for Weaving With Effect From Orientation of High and Low Pile, now abandoned.

A purpose of the invention is to secure variation in pile height throughout a carpet or rug or any portion thereof according to a contour pattern or according to a random distribution, the contour variation in pile height occurring in the same row of pile projections, and the contour pattern or variation in pile height running through the color pattern, if any, independently of the color pattern, and extending through areas of a single color in the color pattern.

A further purpose is to weave a pile fabric such as a carpet or rug over a succession of wavy wires which have different maximum heights.

A further purpose is to weave a pile fabric such as a carpet or rug over a succession of wavy Wires having different maximum heights with interposed straight wires between pairs of wavy wires, and permissibly with different heights in successive noncutting straight wires.

A further purpose is to interpose a plurality of straight wires, preferably of different heights, in between each pair of wavy wires of different maximum heights, providing pile yarn from which the wavy wires can pull pile when they are withdrawn and also providing uniform pile projections.

Further purposes appear in the specification and in the claims.

In the drawings I have chosen to illustrate a few only of the numerous embodiments in which my invention may appear, selecting the forms shown from the standpoints of convenience in illustration, satisfactory operation and clear demonstration of the principles involved.

Figures 1 to 4, inclusive, are diagrammatic views showing the weaving of a fabric in accordance with the invention, Figures 3 and 4 being enlargements respectively of Figures 3 and 4 to illustrate the weave previously produced.

Figure 5 is a diagrammatic sectional perspective of the relationship of adjoining wires in weaving a fabric in accordance with the invention.

Figure 6 is a diagrammatic sectional perspective of a variation in the effect of adjoining wires, showing the relationship where a straight wire is interposed between each pair of wavy wires, and the wavy wires are of different maximum heights.

Figure 7 is a fragmentary sectional perspective of a variation in the wire set, similar to Figure 6 and with different heights of straight wires.

Figure 8 is a fragmentary sectional perspective show ing two straight wires of different heights between each pair of wavy wires of different maximum height.

Figure 9 is a conventional warpvvise Weave diagram 2,820,484 Patented Jan. 21, 195% showing a weave in which the wire combination of the invention may be applied.

Figure 10 is a perspective of one of the wavy wires which may be used in the invention.

in the drawings like numerals refer to like parts throughout.

Describing in illustration but not in limitation and referring to the drawings:

In the prior art pile fabrics such as carpets and rugs have been woven over similar wavy wires, having the same maximum and minimum heights, but with the points of maximum heights located at different lateral positions on the dilferent wires. A single straight wire has also been interposed between such wavy wires.

The prior art patterns thus produced, while involving variations in pile height in the same transverse row, have employed a uniformity of such variations which tends to restrict the texturing which can be obtained, and prevent the intertwining of other pattern effects in the basic texturing. By the present invention, on the other hand, it is possible to produce a major and a minor textured motif, one formed over wavy wires having a high maximum height and another over wavy wires having a low maximum height, and also, if desired, to combine this with a uniform pattern element among the textured elements, by employing straight wires either of the same or different heights, so that if the same pileends are raised over the straight wires and the straight wires take on the wavy effect from the succeeding wavy wires, the wavy wires in turn form straight pile. Many of the resulting patterns are unique from the standpoint of beauty and variety.

In many cases I prefer to employ the wavy wires in adjoining relationship, but in any weave in which the amount of material available in the pile for the purpose of pulling from one pile projection to another is insulticient, as in some tapestry carpet weaves (uncut velvet) or in other cases to obtain special effects, I will interpose straight wires among wavy wires of different maximum height. The straight wires in any case can be all of the same height or of different heights and the number of straight wires in between any pair of wavy wires of different maximum heights may vary with the conditions, being suitably 1, 2, 3, 4, etc., as desired. In fact, any number of straight wires may be used, between a pair of wavy wires, which does not destroy the contour pattern effect created by the wavy Wires.

The weave employed may be of any suitable character, Figures 1 to 4 illustrating a conventional Wilton weave to which the invention has been applied.

in this weave binder warps 70 and '71 are withdrawn from a binder warp beam 72 through a reversing and tensioning device 73. Binder warp '70 is manipulated by binder warp heddle 74 and binder warp 71 is manipulated by binder warp heddle 75. Stuifer warp 77 is taken from stuffer warp beam 76 over tensioning device 73 and is manipulated by stuffer warp heddle '78. it will be evident, of course, that any desired number of stuffer warps may be employed.

Pile warps 80 and 81 are respectively taken from creel frames 82 and 83 through tensioning devices, not shown, and manipulated through lingoe heddles 84 and 35 by any suitable mechanism such as a jacquard to raise and lower the pile warps of the appropriate color at the proper position laterally of the fabric. While only two pile warps are shown, it will be understood, of course, that any de sired number will be employed in multicolor pattern weaving, and that the invention is not limited to any particular number of pile warps of different colors.

A reed is shown at 86.

Starting with the first step in the cycle as shown in Figure 1, binder warp heddle 75, stulfer warp heddle 78 3 and lingoe heddles 84 and 85 are all down, while binder warp heddle 74 is in the upper position. A shot of weft 87 is taken under binder warp 7d and over binder warp 71, over stuifer warp 77 and over pile warps 80 and 81. The beat of reed 86 completes the first step.

At the beginning of the second step as shown in Figure 2, the binder warp heddles 74 and 75 are reversed, stuffer war-p heddle 78 is raised and lingoe heddle 84 is fully raised as the color pattern may require and lingoe heddle 85 is raised half way as the color pattern may require. Wire 83 is inserted under pile warp 8i and above both binder warps, the stuffer warp and pile walp 31. A shot of weft 90 is taken under both pile warps, under binder warp '71, under stuffer warp 77 and over binder warp 79 and the lay is beaten up.

At the beginning of the third step, the stuffer warp heddle 78 is brought down, while the binder warp heddles remain in the same position and lingoe heddles 84 and 85 are brought down. A shot of weft 91 is taken under binder warp 7i and over binder warp 7d, stuffer warp 77 and pile warps 8i and 81. The lay is beaten up.

At the beginning of the fourth step, as shown in Figure 4, binder warp heddles 74 and 75 are reversed, stuifer warpheddle 73 is raised, lingoe heddle $4 is fully raised as the color pattern may require, and lingoe heddle 85 is raised half way as the color pattern may require. Wire 92 is inserted beneath pile warp 8t and above pile warp 81, stulfer warp 77 and both binder warps, and a shot of weft 93 is taken over binder warp 71 and beneath both pile warps, stuffer warp 7'7 and binder warp 7d. The lay is beaten up.

it will be evident that on this single cycle two wires 83 and 92 are inserted. In accordance with the present invention the wires making up the set or some of them are wavy wires which are used in one of the sequences explained herein. At the time that the fabric is made, these wires function in the normal manner as shown in Figures 1 to 4, up to the point of withdrawal of the wires, except that the pile is carried over wires whose height varies throughout their length in at least some cases, the

maximum height of the wavy wires being different on different wires. When the wires are being withdrawn the wires function to readjust the heights of pile loops in the next row preceding the row in which the wire is being withdrawn, producing part of a contour pattern V different on different wires, the high points being relatively high on wire 88,- slightly lower on wire 92 and still lower on wire 94.

Also the high points and low points on adjoining wires do not match up side to side but are variant according to a contour pattern or random distribution.

During withdrawal of a particular wavy wire, the wire pulls the low loops up to the height of the highest portions of the wavy wire which slides through the loop as the wire is withdrawn, and the next wire over which. the same pile warp ends are raised, when it is withdrawn, pulls down certain of the loops in the preceding row, an amount corresponding to the amount that it raises the corresponding end in its row. Those loops in the last row which are already at the full height, however, are not pulled up any higher and therefore do not tend to pull down on loops in the preceding row. Of course, in a Wilton or Brussels weave when a point of pattern change is reached, a particular pile warp end which has been pulled up by the preceding wire will remain fully up be cause there will be no effect on that end by the next wire to pull down loops in the particular row. The final height reached by any loop is thus a function of the initial height proir to withdrawal of the wire of the adjoining loop on the same pile warp in the next transverse pile row following it and of t! e height of the maximum portions of the wire in the particular row where the loop is being formed.

In some cases straight wires are interposed among wavy wires as illustrated in Figure 6. Figure 6 shows a'sequ'ence of a straight wire 88', a high wavy Wire 92, a straight wire 94 desirably of the same height as the straight wire 88', and a low wavy wire 95. This same sequence of straight and wavy wires is repeated throughout the set of wires. The wavy wires have their high and low points located at different lateral positions along the wires in accordance with a contour pattern as previously explained.

The withdrawal of straight wire 88' has no effect on the height of loops in the pile, the withdrawal of wire 88 functioning the same as that of any non-cutting straight wire in the prior art. When, however, the next wire 92, being a wavy wire, is withdrawn, it pulls the next pile loop up to the position corresponding to the maximum height of the wire, at the same time pulling down on the loop which adjoins in the next transverse row of pile projections. Thus, depending upon the amount each adjoining loop is pulled down by withdrawal of wire 92, loops will assume varying heights all lower than the initial height except at a position adjoining a loop formed over Wire 92 at its highest point, in which case the adjoining loop will remain at maximum height.

In a weave having a very low pile in which there is little available pile yarn in a pile loop to permit pulling down, such as a velvet weave, the procedure of providing straight wires in between wave wires is desirable, as it permits the provision of sufiicient pile yarn in the loops initially formed to allow for pulling down under the most rigorous conditions.

When the next wire 94' is withdrawn, it being a straight wire, will have no effect on the height of pile loop and the pile loop previously formed will remain at maximum height.

At a point of pattern change the withdrawal of a succeeding wire does not affect the height of loop over a preceding wire, since different pile warp ends are raised over wires in the different transverse rows, there fore the last pile loop before the pattern change remains at maximum height.

In some cases it is desirable to employ straight wires of different heights, and in Figure 7 I illustrate a straight wire 88 adjoining a wavy wire 92 which in turn adjoins a straight wire 94 of different height from the wire 88, which adjoins a wavy wire 95 of different maximum height from wavy wire 92.

Figure 8 shows that straight wires of different heights can be interposed between each pair of wavy wires of different maximum height. This set of wires is repeated over and over again in the wire set. The sequence in the wire set is low wavy wire 95, high straight wire 94 low straight wire 94', high wavy wire 92, and then repeat throughout the set. Wavy wires 92 and 95 have their high and low points differently disposed laterally to create a contour pattern and desirably have different maximum heights. When the straight wires are withdrawn they have no efiect on the heights of the loopsv but when a wavy wire is withdrawn it does affect the heights of the loops of the same pile warp ends which were last previously raised in the pile.

In all of this discussion it is assumed that the slopes on the wavy wires both toward and away from the head are sufficiently gradual so that the loops can be pulled up to the maximum height of the wire in withdrawing the wire.

Figure 9 shows a weave according to the invention, in which binder warps 7t) and 71 are interwoven with stulfcr warp 77 and wefts 87, 9G, 91 and 93. File warp (lit is raised over wires 88 and 92, which may be of any of the successive forms described, such as successively wavy wires having different maximum heights, or successively wavy wires having different maximum heights interposed by one or more straight wires, all of the wires being noncutting, and the straight wires either being successively of the same height, or successively of different heights, and when two straight wires are used together the straight wires also being either successively of the same height or successively of different heights. Beyond the point of pattern change, loops 101 on pile warp ends 80 are no longer formed, but instead loops 105 are formed on pile Warp ends 81.

The invention may be practiced on any conventional carpet loom by simply changing the wires of the set. Typical examples are Lansdowne or Crompton and Knowles looms.

Figure illustrates a wire constructed in accordance with the invention, having a head 172 of any suitable character to be engaged by the wire mechanism and having low steps 173 within the shed. Intermediate steps 174 and high steps 175 within the shed are provided at intervals along the length of the wire, at the top surface, in accordance with the contour pattern or random arrangement.

The edges are smooth as in conventional practice. Each successive wire has the high points and preferably also the low and intermediate points located at different positions along the length of the wire, for example, at different distances from the end of the wire and also, if desired, closer together or farther apart, depending upon the contour pattern. Also different wires have different maximum heights in the preferred embodiment of the invention.

The low and intermediate portions of the wire are connected by slopes 176 in the direction of withdrawal, while the intermediate and high portions are connected by slopes 177 in the direction of withdrawal. The angles of the slopes with respect to the longitudinal axis of the wire should not exceed and preferably not exceed 10 in accordance with the invention.

It will be evident that the arrangement of the high points, low points and intermediate points on the wire, both as to position and spacing, will depend on the particular pattern. Thus the low and intermediate points in Figure 10 are shown as steps, but the entire contour can be undulating like a sine or other curve.

In view of my invention and disclosure variations and modifications to meet individual whim or particular need will doubtless become evident to others skilled in the art, to obtain all or part of the benefits of my invention without copying the process and fabric shown, and I therefore claim all such insofar as they fall within the reasonable spirit and scope of my claims.

Having thus described my invention, what I claim as new and desire to secure by Letters Patent is:

1. The method of weaving a pile fabric, including binder warps, stuffer warps, pile warps and wefts, which comprises interweaving the various warps and wefts into a fabric, raising pile warps over a first pile wire having a plurality of heights on its upper surface throughout the length which is in the fabric before withdrawal, subsequently raising pile warps over a second pile wire having a plurality of different heights on its upper surface throughout the length which is in the fabric before withdrawal, having different heights at the same lateral position in the fabric from those on the first pile wire, and having different maximum heights of pile wire on its upper surface throughout the length which is in the fabric before withdrawal from the maximum heights on the first pile wire, and subsequently withdrawing the pile wires successively in the order named.

2. The method of weaving a pile fabric, including binder warps, stufier warps, pile warps and wefts, which comprises interweaving the various warps and wefts into a fabric, raising pile warps over a first pile wire having a plurality of heights on its upper surface throughout the length which is in the fabric before withdrawal, subsequently raising pile warps over a second pile wire which is straight on its upper surface throughout the length which is in the fabric before withdrawal, subsequently raising pile warps over a third pile wire having a plurality of different heights on its upper surface throughout the length which is in the fabric before withdrawal and having different heights at the points of maximum height from the heights at the points of maximum height on the first pile wire, at least some of the pile warp ends woven over the third wire, also being woven over the second wire, and subsequently withdrawing the pile wires successively in the order named.

3. The method of weaving a pile fabric, including binder warps, stufier warps, pile warps and wefts, which comprises interweaving the various warps and wefts into a fabric, raising pile warps over a first pile wire having a plurality of heights on its upper surface throughout the length which is in the fabric before withdrawal, subsequently raising pile warps over a second pile wire which is straight on its upper surface throughout the length which is in the fabric before withdrawal, subsequently raising pile warps over a third pile wire having a plurality of different heights on its upper surface throughout the length which is in the fabric before withdrawal and having different heights of its points of maximum height within the fabric before withdrawal from the heights of the points of maximum height on the first pile wire, at least some of the pile warp ends woven over the third wire, also being woven over the second wire, subsequently raising pile warps over a fourth pile wire which is straight on its upper surface throughout the length which is in the fabric before withdrawal but is of a different height from the second pile wire, and subsequently withdrawing the pile wires successively in the order named.

References Cited in the file of this patent UNITED STATES PATENTS 1,714,104 Pearsall May 21, 1929 2,179,375 Matthews Nov. 7, 1939 2,430,559 Dacey Nov. 11, 1947 2,516,465 Jackson July 25, 1950 2,532,903 Groat Dec. 5, 1950 2,546,261 Groat Mar. 27, 1951 2,590,608 Groat Mar. 25, 1952 2,670,013 Groat Feb. 23, 1954 2,713,877 Jackson July 26, 1955 FOREIGN PATENTS 273,409 Great Britain July 6, 1927 916,349 France Aug. 19, 1946 

